Body JEEP LIBERTY 2002 KJ / 1.G User Guide

REMOVAL
(1) Raise and support the vehicle.
(2) Position a lift/jack under the axle and secure
axle to device.
(3) Remove wheels and tires.
(4) Mark propeller shaft and pinion yoke for
installation reference.
(5) Remove propeller shaft and suspend under the
vehicle.
(6) Remove brake drums, parking brake cables and
speed sensor from the axle.
(7) Disconnect the brake hose at the body junction
block.
(8) Remove brakes and backing plates.
(9) Remove vent hose from the axle shaft tube.
(10) Remove the stabilizer bar (Fig. 4).
(11) Remove upper control arm ball joint pinch
bolt from bracket (Fig. 5).
(12) Remove shock absorbers from axle brackets
(Fig. 6).
(13) Loosen all lower control arms mounting bolts
(Fig. 7).
(14) Lower axle enough to remove coil springs and
spring insulators.
(15) Remove lower control arm bolts from the axle
brackets.
(16) Lower and remove the axle.
INSTALLATION
CAUTION: The weight of the vehicle must be sup-
ported by the springs before the lower control arms
are tightened. This must be done to maintain vehi-
cle ride height and prevent premature bushing fail-
ure.(1) Raise the axle under the vehicle.
(2) Install lower control arms onto the axle brack-
ets and loosely install the mounting bolts.
(3) Install coil spring isolators and spring.
(4) Raise axle up until springs are seated.
(5) Install upper control arm ball joint into axle
bracket and tighten pinch bolt to torque specification.
(6) Install shock absorbers and tighten nuts to
torque specification.
(7) Install stabilizer bar and tighten nuts to torque
specification.
(8) Install brake backing plates, parking brake
cables, brake drums and speed sensor.
(9) Install brake hose to the body junction block
and bleed the brakes.
Fig. 4 STABILIZER BAR MOUNTS
1 - STABILIZER BAR MOUNTING BOLTS
2 - LOWER SUSPENSION ARM
Fig. 5 BALL JOINT PINCH BOLT
1 - UPPER BALL JOINT
2 - PINCH BOLT
Fig. 6 SHOCK ABSORBER
1 - UPPER MOUNTING BOLT
2 - LOWER MOUNTING BOLT
KJREAR AXLE - 8 1/4 3 - 91
REAR AXLE - 8 1/4 (Continued)

(10) Install axle vent hose.
(11) Install propeller shaft with reference marks.
(12) Install the wheels and tires.
(13) Add gear lubricant to specifications, if neces-
sary.
(14) Remove lifting device from axle and lower the
vehicle.
(15) Tighten the lower control arm bolts to torque
specification.
ADJUSTMENTS
Ring gears and pinions are supplied as matched
sets only. The identifying numbers for the ring gear
and pinion are etched/marked onto each gear (Fig. 8).
A plus (+) number, minus (±) number or zero (0) is
etched/marked on the face or shaft of the pinion. This
number is the amount (in thousandths of an inch)
the depth varies from the standard depth setting of a
pinion etched with a (0). The standard depth pro-
vides the best gear tooth contact pattern. Refer to
Backlash and Contact Pattern Analysis paragraph in
this section for additional information.
Compensation for pinion depth variance is
achieved with select shims. The shims are placed
behind the rear pinion bearing (Fig. 9).
If a new gear set is being installed, note the depth
variance etched into both the original and replace-
ment pinion. Add or subtract the thickness of the
original depth shims to compensate for the difference
in the depth variances. Refer to the Depth Variance
chart.
Note where Old and New Pinion Marking columns
intersect. Intersecting figure represents plus or
minus the amount needed.Note the etched number on the face of the pinion
gear head (±1, ±2, 0, +1, +2, etc.). The numbers rep-
resent thousands of an inch deviation from the stan-
dard. If the number is negative, add that value to the
required thickness of the depth shims. If the number
is positive, subtract that value from the thickness of
the depth shim. If the number is 0 no change is nec-
essary.
Fig. 7 LOWER SUSPENSION ARM
1 - AXLE BRACKET BOLT
2 - LOWER CONTROL ARM
3 - BODY BRACKET BOLT
Fig. 8 Pinion Gear ID Numbers - Typical
1 - PRODUCTION NUMBERS
2 - DRIVE PINION GEAR DEPTH VARIANCE
3 - GEAR MATCHING NUMBER (SAME AS RING GEAR
NUMBER)
Fig. 9 Adjustment Shim Locations
1 - DIFFERENTIAL HOUSING
2 - COLLAPSIBLE SPACER
3 - REAR PINION BEARING
4 - PINION DEPTH SHIM
5 - PINION GEAR
6 - BEARING CUP
3 - 92 REAR AXLE-81/4KJ
REAR AXLE - 8 1/4 (Continued)

(14) Install pinion gear mate shaft and align holes
in shaft and case.
(15) Install pinion mate shaft lock screw finger
tight to hold shaft during differential installation.
(16) Lubricate all differential components with
hypoid gear lubricant.
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove differential case from axle.
(2) Remove differential bearings from the case
with Puller/Press C-293-PA and Adapters C-293-48
and Plug SP-3289 (Fig. 45).
INSTALLATION
(1) Install differential side bearings with Installer
C-4340 and Handle C-4171 (Fig. 46).
(2) Install differential case in axle.
PINION GEAR/RING GEAR/
TONE RING
REMOVAL
CAUTION: The ring and pinion gears are serviced in
a matched set. Never replace one gear without
replacing the other matched gear.
(1) Mark pinion yoke and propeller shaft for
installation reference.
(2) Remove propeller shaft from pinion yoke and
tie propeller shaft to underbody.
(3) Remove differential from axle housing.
(4) Place differential case in a vise with soft metal
jaw (Fig. 47).
(5) Remove bolts holding ring gear to differential
case.
(6) Drive ring gear from the differential case with
a rawhide hammer.
Fig. 44 CLUTCH PACK AND UPPER SIDE GEAR
1 - SIDE GEAR AND CLUTCH PACK
2 - DIFFERENTIAL CASE
3 - LOWER DISC
Fig. 45 Differential Bearing Puller
1 - PULLER
2 - ADAPTERS
3 - BEARING
4 - DIFFERENTIAL
5 - PLUG
3 - 110 REAR AXLE-81/4KJ
DIFFERENTIAL - TRAC-LOK (Continued)

(4) Position the tube in the flaring tool flush with
the top of the tool bar (Fig. 3). Then tighten the tool
bar on the tube.
(5) Install the correct size adaptor on the flaring
tool yoke screw.
(6) Lubricate the adaptor.
(7) Align the adaptor and yoke screw over the tube
(Fig. 3).
(8) Turn the yoke screw in until the adaptor is
squarely seated on the tool bar.
REMOVAL
REMOVAL - FRONT HOSE
(1) Install prop rod on the brake pedal to keep
pressure on the brake system.
(2) Remove the brake line from the brake hose
inside the engine compartment by the front control
arm bolt (Fig. 4).
(3) Raise and support vehicle.
(4) Remove the brake hose banjo bolt at the cali-
per.
(5) Remove the mounting bolt for the top of the
brake hose at the vehicle (Fig. 5).
(6) Remove the hose.
REMOVAL - REAR BRAKE HOSE
(1) Install prop rod on the brake pedal to keep
pressure on the brake system.
(2) Raise and support the vehicle.
(3) Remove the brake line from the hose at the
body (Fig. 6).
(4) Remove the brake hose mounting bolt at the
top of the hose located at the body (Fig. 6).
(5) Remove the vent tube (Fig. 7).
(6) Remove the two brake lines at the bottom of
the hose located at the axle (Fig. 7).
(7) Remove the mounting bolt for the brake hose
at the axle (Fig. 7).
(8) Remove the hose.
Fig. 3 ISO Flaring
1 - ADAPTER
2 - LUBRICATE HERE
3 - PILOT
4 - FLUSH WITH BAR
5 - TUBING
6 - BAR ASSEMBLY
Fig. 4 INNER FENDER BRAKE LINE
1 - GROMMET
2 - BRAKE LINE
Fig. 5 FRONT BRAKE HOSE
1 - TOP OF FRONT BRAKE HOSE
2 - WHEEL SPEED SENSOR WIRE
3 - UPPER CONTROL ARM
KJBRAKES - BASE 5 - 9
BRAKE LINES (Continued)

INSTALLATION
INSTALLATION - FRONT BRAKE HOSE
(1) Install the hose.
(2) Install the mounting bolt for the top of the
brake hose at the vehicle (Fig. 8).(3) Install the brake hose banjo bolt at the caliper.
(4) Lower the vehicle and remove the support.
(5) Install the brake line to the brake hose inside
the engine compartment by the front control arm
bolt.
(6) Remove the prop rod from the brake pedal.
(7) Bleed the brake system (Refer to 5 - BRAKES -
STANDARD PROCEDURE).
INSTALLATION - REAR BRAKE HOSE
(1) Install the hose.
(2) Install the mounting bolt for the brake hose at
the axle (Fig. 7).
(3) Install the two brake lines at the bottom of the
hose located at the axle (Fig. 7).
(4) Install the vent tube (Fig. 7).
(5) Install the brake hose mounting bolt at the top
of the hose located at the body (Fig. 6).
(6) Install the brake line to the hose at the body
(Fig. 6).
(7) Lower the vehicle and remove the support.
(8) Remove the prop rod.
(9) Bleed the brake system (Refer to 5 - BRAKES -
STANDARD PROCEDURE).
BRAKE PADS / SHOES
DESCRIPTION - REAR DRUM BRAKE
The rear brakes use a leading shoe (primary) and
trailing shoe (secondary) design (Right rear brake is
shown) (Fig. 9).
Fig. 6 BRAKE HOSE AT THE BODY
1 - MOUNTING BOLT
2 - BRAKE HOSE
3 - BRAKE LINE
4 - COIL SPRING
Fig. 7 BRAKE HOSE AT THE AXLE
1 - REAR WHEEL SPEED SENSOR
2 - BRAKE HOSE
3 - VENT HOSE
4 - BRAKE LINES
5 - MOUNTING BOLT
Fig. 8 BRAKE HOSE MOUNTED
1 - COIL SPRING
2 - MOUNTING BOLT
3 - BRAKE HOSE
4 - FRONT OF THE UPPER CONTROL ARM
5 - 10 BRAKES - BASEKJ
BRAKE LINES (Continued)

JUNCTION BLOCK
DESCRIPTION
The junction block and a rear brake proportioning
valve. The valve is not repairable and must be
replaced as an assembly if diagnosis indicates this is
necessary.
OPERATION
PROPORTIONING VALVE
The proportioning valve is used to balance front-
rear brake action at high decelerations. The valve
allows normal fluid flow during moderate braking.
The valve only controls fluid flow during high decel-
erations brake stops. If the primary brake hydraulic
circuit cannot build pressure a by-pass feature is
activated allowing full flow and pressure to the rear
brakes.
DIAGNOSIS AND TESTING - PROPORTIONING
VALVE
The valve controls fluid flow. If fluid enters the
valve and does not exit the valve the combination
valve must be replaced.
REMOVAL
(1) Install prop rod on the brake pedal to keep
pressure on the brake system.
(2) Remove the brake lines from the junction
block.
(3) Remove mounting nuts and bolt and remove
the junction block (Fig. 31).
INSTALLATION
(1) Install the junction block on the mounting
studs.
(2) Install mounting nuts and bolt. Tighten to 14
N´m (125 in. lbs.).
(3) Install brake lines to the junction block and
tighten to 20 N´m (180 in. lbs.).
(4) Bleed ABS brake system (Refer to 5 - BRAKES
- STANDARD PROCEDURE).
PEDAL
DESCRIPTION
A suspended-type brake pedal is used, the pedal
pivots on a shaft mounted in the steering coloumn
support bracket. The bracket is attached to the dash
panel. The unit is serviced as an assembly, except for
the pedal pad.
OPERATION
The brake pedal is attached to the booster push
rod. When the pedal is depressed, the primary
booster push rod is depressed which move the booster
secondary rod. The booster secondary rod depress the
master cylinder piston.
REMOVAL
(1) Remove the knee blocker under the steering
column,(Refer to 23 - BODY/INSTRUMENT PANEL/
KNEE BLOCKER - REMOVAL).
(2) Remove the retainer clip securing the booster
push rod to pedal (Fig. 32).
(3) Remove the brake lamp switch,(Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - REMOVAL).
(4) Remove the nuts securing the pedal to the col-
umn bracket.
(5) Remove the pedal from the vehicle.
INSTALLATION
(1) Install the pedal into the vehicle.
(2) Install the nuts securing the pedal to the col-
umn bracket.
(3) Tighten the nuts to 22.6 N´m (200 in. lbs.).
(4) Lubricate the brake pedal pin and bushings
with Mopar multi-mileage grease.
(5) Install the booster push rod on the pedal pin
and install a new retainer clip (Fig. 32).
(6) Install the brake lamp switch,(Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - INSTALLATION).
(7) Install the knee blocker,(Refer to 23 - BODY/
INSTRUMENT PANEL/KNEE BLOCKER - INSTAL-
LATION).
Fig. 31 JUNCTION BLOCK
1 - JUNCTION BLOCK
2 - MOUNTING NUT
5 - 20 BRAKES - BASEKJ

(6) Remove knee blocker under the steering colum-
n,(Refer to 23 - BODY/INSTRUMENT PANEL/KNEE
BLOCKER - REMOVAL).
(7) Remove retaining clip that secures booster
push rod to brake pedal (Fig. 36).(8) Remove nuts attaching booster to the dash
panel (Fig. 37).
(9) In engine compartment, slide booster studs out
of dash panel, tilt booster upward, and remove
booster from engine compartment.
INSTALLATION
(1) Align and position booster on the dash panel.
(2) Install booster mounting nuts. Tighten nuts
just enough to hold booster in place.
(3) Slide booster push rod onto the brake pedal.
Then secure push rod to pedal pin with retaining
clip.
NOTE: Lubricate the pedal pin and bushing with
Mopar multi-mileage grease before installation.
Fig. 34 Typical Booster Vacuum Test Connections
1 - TEE FITTING
2 - SHORT CONNECTING HOSE
3 - CHECK VALVE
4 - CHECK VALVE HOSE
5 - CLAMP TOOL
6 - INTAKE MANIFOLD
7 - VACUUM GAUGE
Fig. 35 TYPICAL - VACUUM CHECK VALVE AND
SEAL
1 - BOOSTER CHECK VALVE
2 - APPLY TEST VACUUM HERE
3 - VALVE SEAL
Fig. 36 BOOSTER PUSH ROD
1 - BRAKE PEDAL
2 - BOOSTER ROD
Fig. 37 BOOSTER MOUNTING
1 - BRAKE BOOSTER
KJBRAKES - BASE 5 - 23
POWER BRAKE BOOSTER (Continued)

(4) Tighten booster mounting nuts to 22.6 N´m
(200 ft. lbs.).
(5) Install the knee blocker,(Refer to 23 - BODY/
INSTRUMENT PANEL/KNEE BLOCKER - INSTAL-
LATION).
(6) If original master cylinder is being installed,
check condition of seal at rear of master cylinder.
Replace seal if cut, or torn.
(7) Clean cylinder mounting surface of brake
booster. Use shop towel wetted with brake cleaner for
this purpose. Dirt, grease, or similar materials will
prevent proper cylinder seating and could result in
vacuum leak.
(8) Align and install master cylinder on the
booster studs. Install mounting nuts and tighten to
22.6 N´m (200 in. lbs.).
(9) Connect vacuum hose to booster check valve.
(10) Remount the HCU. Tighten bracket mounting
nuts to 22.6 N´m (200 in. lbs.).
(11) Connect and secure the brake lines to HCU or
junction block and master cylinder. Start all brake
line fittings by hand to avoid cross threading.
(12) Connect the wire to fluid level switch at the
bottom of the reservoir.
(13) Fill and bleed base brake system,(Refer to 5 -
BRAKES - STANDARD PROCEDURE).
(14) Verify proper brake operation before moving
vehicle.
MASTER CYLINDER
DESCRIPTION
The master cylinder has a removable nylon reser-
voir. The cylinder body is made of aluminum and
contains a primary and secondary piston assembly.
The cylinder body including the piston assemblies
are not serviceable. If diagnosis indicates an internal
problem with the cylinder body, it must be replaced
as an assembly. The reservoir and grommets are the
only replaceable parts on the master cylinder.
OPERATION
The master cylinder bore contains a primary and
secondary piston. The primary piston supplies
hydraulic pressure to the front brakes. The secondary
piston supplies hydraulic pressure to the rear brakes.
The master cylinder reservoir stores reserve brake
fluid for the hydraulic brake circuits.
DIAGNOSIS AND TESTING - MASTER
CYLINDER/POWER BOOSTER
(1) Start engine and check booster vacuum hose
connections. A hissing noise indicates vacuum leak.
Correct any vacuum leak before proceeding.(2) Stop engine and shift transmission into Neu-
tral.
(3) Pump brake pedal until all vacuum reserve in
booster is depleted.
(4) Press and hold brake pedal under light foot
pressure. The pedal should hold firm, if the pedal
falls away master cylinder is faulty (internal leak-
age).
(5) Start engine and note pedal action. It should
fall away slightly under light foot pressure then hold
firm. If no pedal action is discernible, power booster,
vacuum supply, or vacuum check valve is faulty. Pro-
ceed to the POWER BOOSTER VACUUM TEST.
(6) If the POWER BOOSTER VACUUM TEST
passes, rebuild booster vacuum reserve as follows:
Release brake pedal. Increase engine speed to 1500
rpm, close the throttle and immediately turn off igni-
tion to stop engine.
(7) Wait a minimum of 90 seconds and try brake
action again. Booster should provide two or more vac-
uum assisted pedal applications. If vacuum assist is
not provided, booster is faulty.
POWER BOOSTER VACUUM TEST
(1) Connect vacuum gauge to booster check valve
with short length of hose and T-fitting (Fig. 38).
(2) Start and run engine at curb idle speed for one
minute.
(3) Observe the vacuum supply. If vacuum supply
is not adequate, repair vacuum supply.
(4) Clamp hose shut between vacuum source and
check valve.
(5) Stop engine and observe vacuum gauge.
(6) If vacuum drops more than one inch HG (33
millibars) within 15 seconds, booster diaphragm or
check valve is faulty.
POWER BOOSTER CHECK VALVE TEST
(1) Disconnect vacuum hose from check valve.
(2) Remove check valve and valve seal from
booster.
(3) Use a hand operated vacuum pump for test.
(4) Apply 15-20 inches vacuum at large end of
check valve (Fig. 39).
(5) Vacuum should hold steady. If gauge on pump
indicates vacuum loss, check valve is faulty and
should be replaced.
STANDARD PROCEDURE - MASTER CYLINDER
BLEEDING
A new master cylinder should be bled before instal-
lation on the vehicle. Required bleeding tools include
bleed tubes and a wood dowel to stroke the pistons.
Bleed tubes can be fabricated from brake line.
(1) Mount master cylinder in vise.
5 - 24 BRAKES - BASEKJ
POWER BRAKE BOOSTER (Continued)

FLUID RESERVOIR
REMOVAL
(1) Install prop rod on brake pedal to keep pres-
sure on the brake system.
(2) Remove reservoir cap and siphon fluid into
drain container.
(3) Remove the electrical connector from the fluid
level switch in the reservoir.
(4) Remove the reservoir mounting bolt.
(5) Remove the reservoir from the master cylinder
by pulling upwards.
(6) Remove old grommets from cylinder body.
INSTALLATION
(1) Fill and bleed master cylinder on bench before
installation in vehicle.
CAUTION: Do not use any type of tool to install the
grommets. Tools may cut, or tear the grommets cre-
ating a leak problem after installation. Install the
grommets using finger pressure only.
(2) Lubricate new grommets with clean brake fluid
and Install new grommets in cylinder body. Use fin-
ger pressure to install and seat grommets.
(3) Start reservoir in grommets. Then rock reser-
voir back and forth while pressing downward to seat
it in grommets.
(4) Install the mounting bolt for the reservoir to
the master cylinder.
(5) Reconnect the electrical connector to the fluid
reservoir level switch.(6) Remove the prop rod from the vehicle.
(7) Fill and bleed base brake system,(Refer to 5 -
BRAKES - STANDARD PROCEDURE).
FLUID
DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION
Indications of fluid contamination are swollen or
deteriorated rubber parts.
Swollen rubber parts indicate the presence of
petroleum in the brake fluid.
To test for contamination, put a small amount of
drained brake fluid in clear glass jar. If fluid sepa-
rates into layers, there is mineral oil or other fluid
contamination of the brake fluid.
If brake fluid is contaminated, drain and thor-
oughly flush system. Replace master cylinder, propor-
tioning valve, caliper seals, wheel cylinder seals,
Antilock Brakes hydraulic unit and all hydraulic
fluid hoses.
STANDARD PROCEDURES - MASTER
CYLINDER FLUID LEVEL
Always clean the master cylinder reservoir and cap
before adding fluid. This will prevent dirt from fall-
ing in the reservoir and contaminating the brake
fluid.
The reservoir has a ADD and a FULL mark on the
side (Fig. 42) fill to the FULL mark.
Fig. 41 MASTER CYLINDER
1 - FLUID RESERVOIR
2 - BOOSTER
3 - FLUID LEVEL SWITCH
4 - MASTER CYLINDER
5 - FLUID LEVEL MARKS
Fig. 42 TYPICAL - MASTER CYLINDER FLUID
LEVEL
1 - FLUID LEVEL MARKS
2 - RESERVOIR
5 - 26 BRAKES - BASEKJ
MASTER CYLINDER (Continued)

a linear force against the secondary brake shoe. This
action presses the secondary shoe into contact with
the drum. Once the secondary shoe contacts the
drum, force is exerted through the strut. This force is
transferred through the strut to the primary brake
shoe causing it to pivot into the drum as well.
A gear type ratcheting mechanism is used to hold
the lever in an applied position. Parking brake
release is accomplished by the hand lever release
button.
A parking brake switch is mounted on the parking
brake lever and is actuated by movement of the
lever. The switch, which is in circuit with the red
warning light in the dash, will illuminate the warn-
ing light whenever the parking brakes are applied.
Parking brake is self-adjusting when the lever is
pulled. The cable tensioner, once adjusted at the fac-
tory, should not need further adjustment under nor-
mal circumstances.
ADJUSTMENTS
ADJUSTMENT - LOCK OUT
NOTE: The parking brake is self-adjusting, It can
not be adjusted.
(1) Remove the center floor console (Refer to 23 -
BODY/INTERIOR/FLOOR CONSOLE - REMOVAL).
(2) Pull up on the spring until the tab on the lever
passes the tab on the cable guide and install a punch
in the hole on the side then release (Fig. 46).(3) The park brake system is now locked out to
perform necessary repairs.
CABLES
REMOVAL
(1) Lock out the parking brake cables (Refer to 5 -
BRAKES/PARKING BRAKE - ADJUSTMENTS) (Fig.
46).
(2) Remove the rear seat (Refer to 23 - BODY/
SEATS/SEAT - REMOVAL).
(3) Remove the cable saddle bracket (Fig. 47).
(4) Disconnect the two cables from the front mount
(Fig. 48).
(5) Pull the carpet forward far enough in the rear
to gain access to the two parking brake cables thru
the floor (Fig. 47).
(6) Push the cables thru the floor with the grom-
mets.
(7) Remove the primary brake shoe hold down
spring and separate the shoes to gain access, Then
disconnect the cable from lever on brake shoe.
(8) Remove cables from backing plates by using a
screw driver to break off the tangs on the cable or a
proper sized box end wrench over the tangs.
INSTALLATION
(1) Install the cables into the support plate.
(2) Reconnect the cable to the lever on the brake
shoe, Install the primary brake shoe hold down
spring and the shoes.
Fig. 46 LOCK OUT CABLES
1 - PARKING BRAKE HANDLE
2 - PUNCH
3 - CABLE GUIDE
4 - CABLE
Fig. 47 MOUNTING BRACKETS
1 - MOUNTING SADDLE BRACKET
2 - PARK BRAKE CABLES
3 - CARPET
5 - 30 BRAKES - BASEKJ
PARKING BRAKE (Continued)